Particulate combustion catalyst, particulate filter and exhaust gas purifying apparatus

ABSTRACT

Provided is a particulate combustion catalyst including a carrier formed of monoclinic zirconium oxide particles, and metallic Ag or Ag oxide, which serves as a catalyst component and is supported on the carrier, wherein the amount of the catalyst component is 0.5 to 10 mass %, as reduced to metallic Ag, on the basis of the mass of the carrier, and preferably, the catalyst has a BET specific surface area of 8 to 21 m 2 /g. Also provided are a particulate filter coated with the particulate combustion catalyst; and an exhaust gas cleaning apparatus including a particulate filter coated with the particulate combustion catalyst.

TECHNICAL FIELD

The present invention relates to a particulate combustion catalyst, to a particulate filter, and to an exhaust gas cleaning apparatus. More particularly, the present invention relates to a particulate combustion catalyst which realizes, at low temperature, removal (through oxidation) of particulate matter discharged from a diesel internal combustion engine; to a particulate filter coated with the particulate combustion catalyst; and to an exhaust gas cleaning apparatus including the particulate filter coated with the particulate combustion catalyst.

BACKGROUND ART

Exhaust gas discharged from diesel engines contains particulates (i.e., particulate matter), and release of such a substance into the atmosphere without any treatment is a main cause of air pollution. Therefore, demand has arisen for strict regulation for such a substance. There has been proposed, as effective means for removing particulate matter, a flow-through oxidation catalyst for combustion of soluble organic fractions (SOFs), or a diesel exhaust gas trapping system employing a diesel particulate filter (DPF) for trapping soot. However, for regeneration of such a DPF, particulate matter trapped therein must be continuously removed through oxidation.

Hitherto proposed continuous regeneration systems include a system employing a catalyst including a carrier made of, for example, an oxide of a metal (e.g., aluminum, zirconium, cerium, titanium, or vanadium) or a composite oxide, and an expensive noble metal (e.g., Pt) supported on the carrier (see, for example, Patent Document 1, 2, or 3); and a continuous regeneration method involving NO₂ (see, for example, Patent Document 4). This continuous regeneration method requires provision, upstream of a DPF, of an oxidation catalyst (e.g., Pt) for oxidizing NO into NO₂, and thus involves high cost. In addition, reaction involving NO₂ is affected by the ratio of NO_(x) to C, and many restrictions are imposed on the employment of this method.

Patent Document 1: Japanese Patent Application Laid-Open (kokai) No. H10-047035 Patent Document 2: Japanese Patent Application Laid-Open (kokai) No. 2003-334443 Patent Document 3: Japanese Patent Application Laid-Open (kokai) No. 2004-058013

Patent Document 4: Japanese Patent No. 3012249 DISCLOSURE OF THE INVENTION Problems to be Solved by the Invention

An object of the present invention is to provide a particulate combustion catalyst which realizes removal of soot through oxidation at low temperature without employment of an expensive noble metal, and which enables oxidation reaction to proceed with the aid of only oxygen and thus realizes removal of soot through oxidation at low temperature regardless of the NO_(x) concentration of exhaust gas. Another object of the present invention is to provide a particulate filter coated with the particulate combustion catalyst. Yet another object of the present invention is to provide an exhaust gas cleaning apparatus comprising the particulate filter coated with the particulate combustion catalyst.

Means for Solving the Problems

In order to achieve the aforementioned objects, the present inventors have conducted extensive studies, and as a result have found that the objects can be achieved by providing a particulate combustion catalyst including specific zirconium oxide particles serving as a carrier, and metallic Ag or Ag oxide serving as a catalyst component, the catalyst component being supported on the carrier, wherein the amount of the catalyst component falls within a specific range, and preferably, the catalyst has a BET specific surface area falling within a specific range. The present invention has been accomplished on the basis of this finding.

Accordingly, the present invention provides a particulate combustion catalyst characterized by comprising a carrier formed of monoclinic zirconium oxide particles, and metallic Ag or Ag oxide, which serves as a catalyst component and is supported on the carrier, wherein the amount of the catalyst component is 0.5 to 10 mass %, as reduced to metallic Ag, on the basis of the mass of the carrier.

Preferably, the particulate combustion catalyst of the present invention comprises a carrier formed of monoclinic zirconium oxide particles, and metallic Ag or Ag oxide, which serves as a catalyst component and is supported on the carrier, wherein the amount of the catalyst component is 0.5 to 10 mass %, as reduced to metallic Ag, on the basis of the mass of the carrier, and the catalyst has a BET specific surface area of 8 to 21 m²/g.

More preferably, the particulate combustion catalyst of the present invention comprises a carrier formed of monoclinic zirconium oxide particles, and metallic Ag or Ag oxide, which serves as a catalyst component and is supported on the carrier, wherein the amount of the catalyst component is 1 to 9 mass %, as reduced to metallic Ag, on the basis of the mass of the carrier, and the catalyst has a BET specific surface area of 11 to 20 m²/g.

The present invention also provides a particulate filter characterized by being coated with any of the aforementioned particulate combustion catalysts. The present invention also provides an exhaust gas cleaning apparatus characterized by comprising a particulate filter coated with any of the aforementioned particulate combustion catalysts.

Effects of the Invention

Employment of the particulate combustion catalyst of the present invention realizes removal of soot through oxidation at low temperature without use of an expensive noble metal. When the particulate combustion catalyst is employed, since oxidation reaction proceeds with the aid of only oxygen, soot can be removed through oxidation at low temperature regardless of the NO_(x) concentration of exhaust gas.

BEST MODES FOR CARRYING OUT THE INVENTION

The particulate combustion catalyst of the present invention includes a carrier formed of monoclinic zirconium oxide particles, and metallic Ag or Ag oxide, which serves as a catalyst component and is supported on the carrier. Although various types of zirconium oxide (e.g., monoclinic zirconium oxide and stabilized cubic zirconium oxide) are commercially available, the particulate combustion catalyst of the present invention employs monoclinic zirconium oxide as a carrier.

In the particulate combustion catalyst of the present invention, metallic Ag or Ag oxide must be supported, as a catalyst component, on the aforementioned carrier. Metallic Ag or Ag oxide, which is employed in the present invention, is less expensive than, for example, Pt or Pd. In addition, when metallic Ag or Ag oxide is employed in combination with a specific carrier used in the present invention, further excellent effects are obtained, as compared with the case where a Pt or Pd component is employed. In the present invention, the amount of metallic Ag or Ag oxide supported on the carrier is 0.5 to 10 mass % (preferably, 1 to 9 mass %), as reduced to metallic Ag, on the basis of the mass of the carrier. When the amount of the catalyst component supported is less than 0.5 mass %, the catalyst component may fail to sufficiently exhibit its catalytic effects, and Tig (combustion initiation temperature) becomes higher than 300° C. Even when the amount of the catalyst component supported exceeds 10 mass %, effects commensurate with such a large catalyst component amount cannot be attained. In addition, when the amount of the catalyst component is large, sintering of metal is likely to occur, and the catalyst component is not expected to exhibit its catalytic effects. When the amount of the catalyst component supported is 1 to 9 mass %, as reduced to metallic Ag, on the basis of the mass of the carrier, and the catalyst has a BET specific surface area of 11 to 20 m²/g, Tig becomes 260° C. or lower, although the reason for this has not been elucidated.

The particulate combustion catalyst of the present invention preferably has a BET specific surface area of 8 to 21 m²/g, more preferably 11 to 20 m²/g. When the catalyst has a BET specific surface area of less than 8 m²/g, Tig tends to become higher than 300° C., whereas when the catalyst has a BET specific surface area in excess of 21 m²/g, Tig also tends to become higher than 300° C. As described above, when the catalyst has a BET specific surface area of 11 to 20 m²/g, and the amount of the catalyst component supported is 1 to 9 mass %, as reduced to metallic Ag, on the basis of the mass of the carrier, Tig becomes 260° C. or lower.

As shown in the Examples and Comparative Examples described hereinbelow, a particulate combustion catalyst including a carrier and a catalyst component whose amount is 0.5 to 10 mass %, as reduced to metallic Ag, on the basis of the mass of the carrier exhibits a sufficiently low Tig, whereas a particulate combustion catalyst including a carrier and a catalyst component whose amount is 1 to 9 mass %, as reduced to metallic Ag, on the basis of the mass of the carrier, and having a BET specific surface area of 11 to 20 m²/g exhibits a Tig of 260° C. or lower.

In consideration that the particulate filter of the present invention is produced by causing the particulate combustion catalyst of the present invention to be held on a base, preferably, the surface of the carrier is provided with a binder component such as SiO₂, TiO₂, ZrO₂, or Al₂O₂. When such a binder component is provided on the surface of the carrier, adhesion between the base and the carrier is enhanced, and the catalyst exhibits improved durability and heat resistance.

The particulate combustion catalyst of the present invention may be produced through, for example, the following process. The aforementioned monoclinic zirconium oxide particles are mixed with a binder component (e.g., SiO₂ or alumina sol) and water, and optionally, the resultant mixture is finely milled by means of a milling apparatus (e.g., a ball mill). The resultant dispersion is mixed with an aqueous solution of a water-soluble silver compound, and the mixture is thoroughly stirred, to thereby prepare a slurry. Thereafter, the slurry is dried, and the catalyst-component-supported monoclinic zirconium oxide particles are fired generally at 600 to 900° C., preferably at 730 to 870° C., more preferably at 750 to 850° C. for 10 hours or longer (generally, about 20 hours). When the firing temperature is lower than 600° C., the resultant catalyst tends to have large BET specific surface area and to exhibit high Tig, whereas when the firing temperature exceeds 900° C., the resultant catalyst tends to have small BET specific surface area and to exhibit high Tig (i.e., a practical product is less likely to be produced). When the firing temperature is 600 to 900° C., the resultant catalyst tends to have a BET specific surface area of about 8 to about 21 m²/g and to exhibit a Tig of 300° C. or lower, whereas when the firing temperature is 730 to 870° C., the resultant catalyst tends to have a BET specific surface area of about 11 to about 20 m²/g and to exhibit a Tig of 260° C. or lower. When the firing time is shorter than 10 hours, a catalyst having intended characteristics may fail to be produced, whereas even when the firing time exceeds 50 hours, effects commensurate with such a long firing time are not obtained.

The particulate filter of the present invention may assume any known form of particulate filter, but preferably has a three-dimensional structure. Specific examples of filters having a three-dimensional structure include a wall-through filter, a flow-through honeycomb filter, a wire mesh filter, a ceramic fiber filter, a metallic porous filter, a particle-charged filter, and a foam filter. Examples of the material of the base include ceramic materials such as cordierite and SiC; Fe—Cr—Al alloys; and stainless steel alloys.

The exhaust gas cleaning apparatus of the present invention, which includes therein the aforementioned particulate filter of the present invention, will be readily appreciated by those skilled in the art.

Next will be described a method for producing the particulate filter of the present invention. A base filter (e.g., a wire mesh filter) is coated with a slurry prepared as described above. The slurry-coated filter is fired generally at 600 to 900° C., preferably at 730 to 870° C., more preferably at 750 to 850° C. for 10 hours or longer (generally, about 20 hours). The total catalyst coating amount is preferably 10 to 100 g/L (for a wall-flow DPF) or about 50 to about 150 g/L (for a wire mesh DPF). When the total catalyst coating amount is excessively small, sufficient performance fails to be attained, whereas when the total catalyst coating amount is excessively large, back pressure to exhaust gas increases.

The present invention will next be described in detail with reference to Examples and Comparative Examples.

In the below-described Examples and Comparative Examples, the Tig (combustion initiation temperature) of a powdery catalyst was determined through the following method.

Evaluation of Powdery Catalyst by use of Simulated Exhaust Gas

Particulate combustion catalyst powder (20 mg) and carbon (Printex-V (toner carbon), product of Degussa) (2 mg) were mixed for two minutes by means of an agate mortar, and the mixture was fixed at a center portion of a quartz reaction tube by use of quartz wool. While a circulation gas having the below-described composition was caused to flow through the quartz reaction tube at the below-described flow rate, the temperature of the reaction tube was elevated at the below-described temperature elevation rate by means of an electric furnace, and CO and CO₂ concentrations were measured at the outlet of the reaction tube by means of an infrared analyzer. The temperature as measured at the inlet of the catalyst-containing reaction tube when CO₂ concentration reached 30 ppm (i.e., electric furnace control temperature) was regarded as Tig (combustion initiation temperature).

Gas composition: O₂: 10%, N₂: 90%

Flow rate: 400 cc/min

Temperature elevation rate: 10 degrees (° C.)/min

Examples 1 to 6 and Comparative Examples 1 to 9

Monoclinic zirconium oxide (ZrO₂) particles or γ-alumina (Al₂O₃) particles were employed as a carrier. The powdery carrier was mixed with aqueous silver nitrate solution or nitric acid solution of (dinitrodiamine)Pt so that the amount of a catalyst component supported (as reduced to metallic silver or metallic platinum) on the basis of the mass of the carrier was adjusted as shown in Table 1. The resultant mixture was stirred for one hour. Thereafter, water was evaporated under heating, followed by drying at 120° C. The thus-dried product was fired at 750° C. for 20 hours, to thereby produce a particulate combustion catalyst. Table 1 shows the BET specific surface area and Tig of the particulate combustion catalyst.

TABLE 1 Catalyst com- Amount BET specific Carrier ponent supported surface area Tig Comparative ZrO₂ Ag 0 mass %  25.6 m²/g 384° C. Example 1 Example 1 ZrO₂ Ag 0.5 mass %    20.7 m²/g 300° C. Example 2 ZrO₂ Ag 1 mass %  19.2 m²/g 251° C. Example 3 ZrO₂ Ag 2 mass %  16.0 m²/g 245° C. Example 4 ZrO₂ Ag 5 mass %  15.3 m²/g 256° C. Example 5 ZrO₂ Ag 9 mass %  13.1 m²/g 258° C. Example 6 ZrO₂ Ag 10 mass %   10.2 m²/g 264° C. Comparative Al₂O₃ Ag 0 mass % 147.8 m²/g 479° C. Example 2 Comparative Al₂O₃ Ag 1 mass % 146.9 m²/g 487° C. Example 3 Comparative Al₂O₃ Ag 2 mass % 146.4 m²/g 476° C. Example 4 Comparative Al₂O₃ Ag 5 mass % 136.8 m²/g 441° C. Example 5 Comparative Al₂O₃ Pt 0 mass % 147.8 m²/g 479° C. Example 6 Comparative Al₂O₃ Pt 1 mass % 142.8 m²/g 458° C. Example 7 Comparative Al₂O₃ Pt 2 mass % 151.2 m²/g 459° C. Example 8 Comparative Al₂O₃ Pt 5 mass % 147.8 m²/g 461° C. Example 9

As is clear from data shown in Table 1 (Examples 1 to 6), when Ag (i.e., a catalyst component) was supported on a carrier formed of monoclinic zirconium oxide particles so that the amount of the catalyst component was adjusted to 0.5 to 10 mass % (as reduced to metallic Ag) on the basis of the mass of the carrier, the resultant catalyst exhibited a Tig of 300° C. or lower and had a BET specific surface area of 8 to 21 m²/g, and when the catalyst component was supported on the carrier so that the amount of the catalyst component was adjusted to 1 to 9 mass % (as reduced to metallic Ag) on the basis of the mass of the carrier, the resultant catalyst exhibited a Tig of 260° C. or lower and had a BET specific surface area of 11 to 20 m²/g. In contrast, as is clear from data obtained in Comparative Examples 2 to 9, when Al₂O₃ was employed as a carrier in place of ZrO₂, or when Pt was employed as a catalyst component in place of Ag, the Tig of the resultant catalyst was not low.

Examples 7 to 11 and Comparative Example 10

Monoclinic zirconium oxide (ZrO₂) particles were employed as a carrier. The powdery carrier was mixed with an aqueous silver nitrate solution so that the amount of a catalyst component supported (as reduced to metallic silver) on the basis of the mass of the carrier was adjusted as shown in Table 2. The resultant mixture was stirred for one hour. Thereafter, water was evaporated under heating, followed by drying at 120° C. The thus-dried product was fired at 750° C. for 20 hours, to thereby produce a particulate combustion catalyst. Table 2 shows the BET specific surface area and Tig of the particulate combustion catalyst.

TABLE 2 Car- Catalyst Amount BET specific rier component supported surface area Tig Comparative ZrO₂ Ag 0 mass % 10.0 m²/g  396° C. Example 10 Example 7 ZrO₂ Ag 0.5 mass %  9.5 m²/g 300° C. Example 8 ZrO₂ Ag 1 mass % 8.5 m²/g 268° C. Example 9 ZrO₂ Ag 2 mass % 8.4 m²/g 269° C. Example 10 ZrO₂ Ag 5 mass % 8.4 m²/g 274° C. Example 11 ZrO₂ Ag 10 mass %  8.3 m²/g 269° C.

Examples 12 to 18

Monoclinic zirconium oxide particles were employed as a carrier. The powdery carrier was mixed with an aqueous silver nitrate solution so that the amount of a catalyst component supported (as reduced to metallic silver) was adjusted to 1 mass % on the basis of the mass of the carrier, and the resultant mixture was stirred for one hour. Thereafter, water was evaporated under heating, followed by drying at 120° C. The thus-dried product was fired at a temperature shown in Table 3 for 20 hours, to thereby produce a particulate combustion catalyst. Table 3 shows the BET specific surface area and Tig of the particulate combustion catalyst.

TABLE 3 BET specific Firing temperature surface area Tig Example 12 600° C. 27.5 m²/g 277° C. Example 13 650° C. 23.2 m²/g 268° C. Example 14 700° C. 21.1 m²/g 271° C. Example 15 750° C. 19.2 m²/g 251° C. Example 16 800° C. 13.9 m²/g 259° C. Example 17 850° C. 11.9 m²/g 252° C. Example 18 900° C.  6.2 m²/g 275° C.

Examples 19 to 24

Monoclinic zirconium oxide particles were employed as a carrier. The powdery carrier was mixed with an aqueous silver nitrate solution so that the amount of a catalyst component supported (as reduced to metallic silver) was adjusted to 1 mass % on the basis of the mass of the carrier, and the resultant mixture was stirred for one hour. Thereafter, water was evaporated under heating, followed by drying at 120° C. The thus-dried product was fired at 750° C. for a period of time shown in Table 4, to thereby produce a particulate combustion catalyst. Table 4 shows the BET specific surface area and Tig of the particulate combustion catalyst.

TABLE 4 BET specific Firing time surface area Tig Example 19 10 hours 19.1 m²/g 259° C. Example 20 15 hours 18.0 m²/g 256° C. Example 21 20 hours 19.2 m²/g 251° C. Example 22 25 hours 15.1 m²/g 254° C. Example 23 30 hours 14.7 m²/g 255° C. Example 24 50 hours 12.9 m²/g 258° C. 

1. A particulate combustion catalyst characterized by comprising a carrier formed of monoclinic zirconium oxide particles, and metallic Ag or Ag oxide, which serves as a catalyst component and is supported on the carrier, wherein the amount of the catalyst component is 0.5 to 10 mass %, as reduced to metallic Ag, on the basis of the mass of the carrier.
 2. A particulate combustion catalyst according to claim 1, which is produced through firing at 600 to 900° C. for 10 hours or longer.
 3. A particulate combustion catalyst according to claim 1, which has a BET specific surface area of 8 to 21 m²/g.
 4. A particulate combustion catalyst according to claim 1, which exhibits a combustion initiation temperature (Tig) of 300° C. or lower.
 5. A particulate combustion catalyst characterized by comprising a carrier formed of monoclinic zirconium oxide particles, and metallic Ag or Ag oxide, which serves as a catalyst component and is supported on the carrier, wherein the amount of the catalyst component is 1 to 9 mass %, as reduced to metallic Ag, on the basis of the mass of the carrier, and the catalyst has a BET specific surface area of 11 to 20 m²/g.
 6. A particulate combustion catalyst according to claim 5, which exhibits a combustion initiation temperature (Tig) of 260° C. or lower.
 7. A particulate combustion catalyst according to claim 1, which is produced through firing at 730 to 870° C. for 10 hours or longer.
 8. A particulate filter characterized by comprising a base coated with a particulate combustion catalyst as recited in claim
 1. 9. An exhaust gas cleaning apparatus characterized by comprising a particulate filter coated with a particulate combustion catalyst as recited in claim
 1. 10. A particulate combustion catalyst characterized by comprising a carrier formed of monoclinic zirconium oxide particles, and metallic Ag or Ag oxide, which serves as a catalyst component and is supported on the carrier, wherein the amount of the catalyst component is 0.5 to 10 mass %, as reduced to metallic Ag, on the basis of the mass of the carrier.
 11. A particulate combustion catalyst according to claim 10, which is produced through firing at 600 to 900° C. for 10 hours or longer.
 12. A particulate combustion catalyst according to claim 10, which has a BET specific surface area of 8 to 21 m²/g.
 13. A particulate combustion catalyst according to claim 11, which has a BET specific surface area of 8 to 21 m²/g.
 14. A particulate combustion catalyst according to claim 10, which exhibits a combustion initiation temperature (Tig) of 300° C. or lower.
 15. A particulate combustion catalyst according to claim 13, which exhibits a combustion initiation temperature (Tig) of 300° C. or lower.
 16. A particulate combustion catalyst characterized by comprising a carrier formed of monoclinic zirconium oxide particles, and metallic Ag or Ag oxide, which serves as a catalyst component and is supported on the carrier, wherein the amount of the catalyst component is 1 to 9 mass %, as reduced to metallic Ag, on the basis of the mass of the carrier, and the catalyst has a BET specific surface area of 11 to 20 m²/g.
 17. A particulate combustion catalyst according to claim 16, which exhibits a combustion initiation temperature (Tig) of 260° C. or lower.
 18. A particulate combustion catalyst according to claim 10, which is produced through firing at 730 to 870° C. for 10 hours or longer.
 19. A particulate combustion catalyst according to claim 11, which is produced through firing at 730 to 870° C. for 10 hours or longer.
 20. A particulate combustion catalyst according to claim 12, which is produced through firing at 730 to 870° C. for 10 hours or longer.
 21. A particulate combustion catalyst according to claim 15, which is produced through firing at 730 to 870° C. for 10 hours or longer.
 22. A particulate filter characterized by comprising a base coated with a particulate combustion catalyst as recited in claim
 10. 23. A particulate filter characterized by comprising a base coated with a particulate combustion catalyst as recited in claim
 11. 24. A particulate filter characterized by comprising a base coated with a particulate combustion catalyst as recited in claim
 12. 25. A particulate filter characterized by comprising a base coated with a particulate combustion catalyst as recited in claim
 15. 26. An exhaust gas cleaning apparatus characterized by comprising a particulate filter coated with a particulate combustion catalyst as recited in claim
 10. 27. An exhaust gas cleaning apparatus characterized by comprising a particulate filter coated with a particulate combustion catalyst as recited in claim
 11. 28. An exhaust gas cleaning apparatus characterized by comprising a particulate filter coated with a particulate combustion catalyst as recited in claim
 12. 29. An exhaust gas cleaning apparatus characterized by comprising a particulate filter coated with a particulate combustion catalyst as recited in claim
 15. 